Polymer Construction Studs and Sheathing

The present application claims the benefit of U.S. provisional patent application 63/367,748 filed Jul. 6, 2022, and also the benefit of U.S. provisional patent application 63/296,330 filed Jan. 4, 2022, each of like title and inventorship, the teachings and entire contents which are incorporated herein by reference.

The present invention pertains generally to static structures, for exemplary purposes such as buildings but not solely limited thereto. In more particular manifestations, improved and cost-effective construction components are used to construct a building. These construction components desirably facilitate construction, while also providing enhanced and beneficial characteristics.

Wood has long been a preferred material for the construction of buildings. Wood is readily cut to dimension by construction workers at a job site using low cost and much harder steel and carbide saws, is easily and securely fastened using low cost fasteners, is extremely strong for a given weight, resists sag, and is generally low cost. Where wood has been used to construct a building, future remodeling projects are readily accomplished, once again owing to ready cutting and fastening at the job site.

Unfortunately, wood is limited in length to that of the undamaged portions of a tree and to basic shapes that are readily cut at a saw mill. Even when properly cut, the wood may warp or twist during drying or subsequent thereto in response to environmental humidity changes. Wood is also readily damaged by water, fungi, and insects such as termites. Furthermore, wood is not universally available for low cost, particularly in the more arid regions of the world and during periods of high demand. While competing natural products such as steel, stone, cement, bricks, and ceramic tiles have much greater resistance to environmental and insect damage, they are both more expensive to acquire and far more difficult to cut, shape, fasten, and subsequently remodel.

One popular commercial product that has been developed to augment or replace lumber, particularly for exterior decking but for many other projects, is a polymer wood composite (PWC). Exemplary U.S. patents, the teachings which are incorporated herein by reference, include: U.S. Pat. No. 6,153,293 by Dahl et al, entitled “Extruded wood polymer composite and method of manufacture”; U.S. Pat. No. 6,651,398 by Gregori, entitled “Decking assembly and decking kit with hold-down clip”; and U.S. Pat. No. 6,958,185 by Zehner, entitled “Multilayer synthetic wood component”.

PWC products combine the inherent strength of wood cellulose with the water, fungi, and insect resistance of plastic by extruding a polymer together with reduced-size wood fibers such as sawdust or chipped wood. Most commonly, PWC is extruded into standard dimensional lumber sizes, and is a solid product. The resulting boards are very heavy, undesirably expensive, and remain susceptible to warpage and degradation over time when in contact with moisture or in very humid environments.

Other artisans have designed plastic products that in at least some embodiments are free of wood entirely, and are likewise intended to augment or replace lumber. Exemplary U.S. patents, the teachings which are incorporated herein by reference, include: U.S. Pat. No. 5,783,286 by DiNicola, entitled “Hollow-core plastic structural lumber alternative”; U.S. Pat. Nos. 6,881,367 and 6,890,637 by Baker, entitled “Composite materials, articles of manufacture produced therefrom, and methods for their manufacture”; and U.S. Pat. No. 8,065,848 by Carlson et al, entitled “Structural member”.

There are a multitude of challenges associated with the use of plastic instead of wood. Primary among these, but not solely limited thereto, are: the greater expense of the plastic material; the difficulties fabricating and cooling the material without sag or warp; maintaining geometry after installation into a building, again without sag or warp; recycling the plastic at the end of the life of a building; and providing suitable fastener adherence to the plastic lumber. One common technique to improve the structural integrity of plastic is to incorporate a filler, typically a fibrous material. One widely used filler is glass fiber, which benefits strength, sag, and warp, and in some cases can also improve fastener adherence. However, glass fiber is very abrasive, and so causes greatly accelerated wear within the manufacturing and building construction equipment. During cutting and drilling, the glass fiber dust can be irritating and hazardous, in some cases endangering the health of the workers and thereby mandating the use of special masks or respirators. Furthermore, at the end of life, fibrous fillers also make recycling far more difficult, if not impossible, since the fibers are extremely difficult or impossible to reasonably separate from the plastic of different composition. Consequently, while the presently available and known wood-free plastic lumber products address some of the challenges, none adequately address all.

In addition to dimensional lumber applications, there are also other applications where plastic compositions will desirably provide alternatives to wood and other building materials. Paneling is one such area. Exemplary U.S. patents, the teachings which are incorporated herein by reference, include: U.S. Pat. No. 3,886,705 by Cornland, entitled “Hollow structural panel of extruded plastics material and a composite panel structure formed thereof”; U.S. Pat. No. 5,294,472 by Arnold et al, entitled “Oblique web multiple surface panels fabricated of aromatic polycarbonates”; U.S. Pat. No. 5,706,620 by De Zen, entitled “Thermoplastic structural system and components therefor and method of making same”; U.S. Pat. No. 8,590,271 by Thiagarajan et al, entitled “Multi-wall structural components having enhanced radiatransmission capability”; Des U.S. Pat. No. 405,545 by Forbis, entitled “Fence plank”; Des U.S. Pat. No. 490,544 by Givoni, entitled “Structural panel”; Des U.S. Pat. No. 500,370 by Givoni, entitled “Structural panel”; Des U.S. Pat. No. 503,000 by Forbis, entitled “Fence panel”; and Des U.S. Pat. No. 564,106 by Amato, entitled “Deck panel”. These building panels offer similar opportunity and challenges to those described herein above with reference to dimensional lumber.

Additional patents of varying relevance, the relevant teachings and contents which are incorporated herein by reference, include: U.S. Pat. No. 3,364,638 by Santangelo, entitled “Composite plastic and corrugated panel”; U.S. Pat. No. 3,435,575 by Pottiez, entitled “Process and extruded elements for industrial manufacturing of furniture, furniture components and similar constructions”; U.S. Pat. No. 3,450,593 by Fossier et al, entitled “Panel having rims bonded with glass fibers and polyester resin”; U.S. Pat. No. 3,662,507 by Espeland, entitled “Preformed building wall construction”; U.S. Pat. No. 3,732,138 by Almog, entitled “Panel constructions”; U.S. Pat. No. 3,783,563 by Moore, entitled “Prefabricated building components”; U.S. Pat. No. 3,819,466 by Winfield et al, entitled “Reinforced and insulating building panel”; U.S. Pat. No. 3,948,347 by Rutledge, entitled “Acoustical panel”; U.S. Pat. No. 3,974,612 by Karner, entitled “Structural element”; U.S. Pat. No. 4,035,536 by Morrison, entitled “Sandwich panel core”; U.S. Pat. No. 4,441,291 by Sokoler et al, entitled “Panel, in particular for self-supporting roof structures and self-supporting roof structures assembled of such panels”; U.S. Pat. No. 4,606,959 by Hillinger, entitled “Honeycomb panel”; U.S. Pat. No. 4,718,213 by Butterfield, entitled “Decorative beam assembly”; U.S. Pat. No. 4,749,601 by Hillinger, entitled “Composite structure”; U.S. Pat. No. 5,030,662 by Banerjie, entitled “Construction material obtained from recycled polyolefins containing other polymers”; U.S. Pat. No. 5,052,164 by Sandow, entitled “Method for manufacturing a panel assembly and structure resulting therefrom”; U.S. Pat. No. 5,471,809 by Frankel, entitled “Reinforced plastic structural support member”; U.S. Pat. No. 5,789,477 by Nosker et al, entitled “Composite building materials from recyclable waste”; U.S. Pat. No. 6,497,956 by Phillips et al, entitled “Structural recycled plastic lumber”; U.S. Pat. Nos. 6,986,934, 7,169,460, 7,211,310, 7,419,717, 7,763,345, 8,021,741, 8,658,274, and 8,834,992 by Chen et al, each entitled “Thermoplastic planks and methods for making the same”; U.S. Pat. No. 7,795,329 by Nosker et al, entitled “Use of recycled plastics for structural building forms”; U.S. Pat. No. 8,629,221 by Nosker et al, entitled “Compositions and methods of making plastic articles”; U.S. Pat. No. 8,752,348 by Bowman, entitled “Composite pre-formed construction articles”; Des U.S. Pat. No. 211,517 by Pettler, entitled “Extruded cellular panel for furniture”; Des U.S. Pat. No. 423,116 by Gregori, entitled “Decking”; Des U.S. Pat. No. 431,658 by Gregori, entitled “Decking”; Des U.S. Pat. No. 451,612 by Thibault et al, entitled “Top of a deck member”; Des U.S. Pat. No. 453,045 by Ohanesian, entitled “Post for a storage shed”; Des U.S. Pat. No. 473,955 by Gregori, entitled “Structural member”; Des U.S. Pat. No. 474,286 by Gregori, entitled “Structural member”; Des U.S. Pat. No. 485,373 by Morton et al, entitled “Deck plank extrusion”; Des U.S. Pat. No. 531,324 by Takagi, entitled “Building board material”; Des U.S. Pat. No. 564,678 by Simko, entitled “Construction member”; and Des U.S. Pat. No. 585,568 by Kikuchi, entitled “Synthetic board for building purposes”.

As may be apparent, in spite of the enormous advancements and substantial research and development that has been conducted, there still remains a need for a cost-effective alternative to wood lumber that preserves the ready cutting and fastening benefits of wood, is recyclable, and is readily cleaned, while overcoming both geometric limitations and susceptibility to environmental and insect damage and warpage.

In addition to the foregoing patents, Webster's New Universal Unabridged Dictionary, Second Edition copyright 1983, is incorporated herein by reference in entirety for the definitions of words and terms used herein.

In a first manifestation, the invention is a building construction stud, comprising a plastic generally contiguous outer wall defining a length, width, depth, cross-section transverse to the length, and an interior, the interior contained substantially within the plastic generally contiguous outer wall; at least one void space longitudinally extensive parallel with the plastic generally contiguous outer wall and contained substantially within the interior; and at least one fastener anchoring and structurally reinforcing member contained substantially within the interior.

In a second manifestation, the invention is, in combination, a building construction stud, a building construction sheathing panel, and at least one fastener affixing the building construction sheathing panel to the building construction stud. The building construction stud comprises a plastic generally contiguous stud outer wall defining a stud length, stud width, stud depth, stud cross-section transverse to the stud length, and a stud interior. The stud interior is contained substantially within the plastic generally contiguous stud outer wall. The plastic stud outer wall has a generally planar first sheathing face parallel with the stud outer wall longitudinal and width axes, a generally planar sheathing second face distal to and generally parallel with the generally planar first sheathing face, a generally planar stud first side wall parallel with the stud outer wall longitudinal and depth axes, a generally planar second side wall distal to and generally parallel with the generally planar first side wall, and at least one void space longitudinally extensive parallel with the plastic generally contiguous stud outer wall and contained substantially within the stud interior. The plastic stud outer wall length is greater than the plastic stud outer wall depth, the plastic generally contiguous stud outer wall cross-section defines a rectangle, and the plastic generally contiguous stud outer wall depth is greater than the plastic generally contiguous stud outer wall width. A plurality of longitudinally extensive stud wall ribs protrude internally from the generally planar first sheathing face. The stud wall ribs are configured to increase stiffness and strength, and also configured to enhance fastener engagement. The at least one fastener penetrates each of the building construction sheathing panel, the generally planar first sheathing face, and the plurality of longitudinally extensive stud wall ribs, and thereby affixes the building construction sheathing panel to the building construction stud.

In a third manifestation, the invention is, in combination, a building construction stud and a building construction stud end cap. The building construction stud comprises a plastic generally contiguous stud outer wall defining a stud length, stud width, stud depth, stud cross-section transverse to the stud length, and a stud interior, the stud interior contained substantially within the plastic generally contiguous stud outer wall. At least one void space is longitudinally extensive parallel with the plastic generally contiguous stud outer wall and is contained substantially within the stud interior. A generally planar first sheathing face is parallel with the stud outer wall longitudinal and width axes. A generally planar second sheathing face is distal to and generally parallel with the generally planar first sheathing face. A generally planar first stud side wall is parallel with the stud outer wall longitudinal and depth axes. A generally planar second stud side wall is distal to and generally parallel with the generally planar first stud side wall. The building construction stud end cap comprises a terminating cap orthogonal to and abutted with each of the generally planar first sheathing face, the generally planar second sheathing face, the generally planar first stud side wall, and the generally planar second stud side wall. At least one end cap side wall rises from the terminating cap and is inserted within the stud interior. An end cap top face is bordered by the at least one end cap side wall and is distal to the terminating cap.

Exemplary embodiments of the present invention solve inadequacies of the prior art by providing a homogenous and unitary plastic building construction stud having a plastic generally contiguous outer wall; at least one void space longitudinally extensive parallel with the plastic generally contiguous outer wall and contained substantially within the interior; and at least one fastener anchoring and structurally reinforcing member contained substantially within the interior.

The present invention and the preferred and alternative embodiments have been developed with a number of objectives in mind. While not all of these objectives are found in every embodiment, these objectives nevertheless provide a sense of the general intent and the many possible benefits that are available from embodiments of the present invention.

A first object of the invention is to provide improved and cost-effective construction components that are used to construct a building. As a corollary thereto, it is an object of the invention to require less material for a given length and strength requirement, which is beneficial both in cost of materials and also during manufacturing, since less material generally cools more quickly. A second object of the invention is for those construction components to facilitate on-site building construction and remodeling by being readily and safely cut and otherwise worked by construction workers, and readily cleaned when so required. As a corollary thereto, it is an object of the present invention to use a material that is not hazardous to a construction worker during building construction. Another object of the present invention is to reduce susceptibility to environmental and insect damage. A further object of the invention is for those construction components to be readily recycled at the end of building life. Yet another object of the present invention is to provide suitable fastener adherence.

Manifested in the preferred embodiment, the present invention provides a polymer construction component having a generally contiguous outer wall, at least one and preferably a plurality of longitudinally extensive hollow portions or void spaces within the outer wall, and a structurally reinforcing and fastener anchoring internal web that in some embodiments divides and thereby defines the hollow portions.

In a preferred embodiment of the invention illustrated in, a construction studis comprised of an outer wall, at least one secondary fastener anchoring and internal reinforcing member, and a void space. In this preferred embodiment, at least two secondary fastener anchoring and internal reinforcing membersare provided, and arranged to define an X-shaped cross-section therebetween, creating a semi-open profile with excellent strength to weight ratio.

While illustrated as having substantially constant thickness, outer wallwill in some embodiments be slightly thicker on narrower longitudinally extensive faces than on the wider faces. In those embodiments, the additional wall thickness will be selected to assist with the securement of nails and screws. Again for exemplary and non-limiting purpose, a 2×4 dimensional stud has actual dimensions of 1.5×3.5 inches. The 1.5 inch faces are normally in contact with walls, ceilings, and the like. Consequently, fasteners securing drywall or other paneling or sheathing will pass through the 1.5 inch face. The extra thickness on the 1.5 inch face will then provide a somewhat more secure attachment. As referenced in, outer wallincludes a generally planar first sheathing facethat is parallel to the outer wall longitudinal and width axes. A generally planar sheathing second faceis distal to and generally parallel with the generally planar first sheathing face. Side walls,are perpendicular to the first and second sheathing faces,, and comprise generally planar faces parallel with the outer walllongitudinal and depth axes.

These aforementioned definitions of width and depth axes are provided merely for convenience in communicating the various faces of outer wall, and are chosen herein to correspond to a building wall when studis being used as a vertical wall stud. In such case, the building wall height axis is parallel to the outer walllongitudinal axis, the building wall width axis is parallel to the outer wallwidth axis, and the building wall depth or thickness axis is parallel to the outer walldepth axis. Nevertheless, such designations are for convenience and understanding only, and will be understood to not be limiting to the present invention in any way.

The interior of preferred embodiment construction studcomprises two secondary fastener anchoring and internal reinforcing membersarranged in an X-pattern, creating four void spaceseach of a triangular prism geometry. In preferred embodiment construction stud, spacesbetween internal reinforcing membersare open to the atmosphere. While not preferred for a number of reasons, including more difficult initial fabrication, more difficult installation by construction workers, and much more difficult recycling at end-of-building-life, in some alternative embodiments these spaces are filled with suitable solid or foamed material, for exemplary and non-limiting purposes including wood, resins and plastics, metals, ceramics or cementitious materials, or even combinations or composites of the above. In yet further alternative embodiments, only portions of these spaces are filled with additional material, such as at the ends or at periodic or predetermined intermediate locations.

Internal reinforcing membershelp to reduce the transfer of heat and sound, while also improving upon strength to weight ratios. Furthermore, these internal reinforcing membersprovide a second anchor point for fasteners installed into preferred embodiment construction stud. This is extremely beneficial for ensuring that the fasteners are securely anchored, by providing extra grip that helps to prevent the fastener from backing out. While a single pair of internal reinforcing membersarranged in an X-pattern could in some embodiments be sufficient, preferred embodiment construction studinstead is provided with three pairs of internal reinforcing members, each pair arranged in an X-pattern. Each pair is separated from an adjacent pair by a cell divider and internal reinforcing memberthat both adds reinforcing strength to preferred embodiment construction studand divides the interior of preferred embodiment construction studinto several smaller sections.

One particularly noteworthy benefit of subdividing the internal space within preferred embodiment construction studis that a fastener of reasonable length is much more likely to not only penetrate outer wall, but also penetrate at least one and potentially several of the internal reinforcing members,. As already noted above, achieving this is extremely beneficial for ensuring that the fasteners are and remain securely anchored.

Preferred embodiment construction studis preferably fabricated entirely and solely from plastic, including virgin or recycled content in any suitable combination, and is particularly suited for inner, non-load bearing applications. In a most preferred embodiment, the plastic composition that forms the bulk of studis homogenous and uniform, which greatly facilitates recycling. Nevertheless, it will also be understood that even in some of the most preferred embodiments where the bulk of studis homogenous and uniform, nominal surface coatings, treatments, or finishes of different composition or lacking homogeneity or uniformity with respect to the bulk of studwill also be applied.

A benefit of plastic is that it is not always subject to the same degree and timing of price fluctuation as wood and other natural materials. Additionally it can be completely recyclable, particularly where used internally and so not exposed to consequential amounts of ultra-violet light. A preferred material can be ground and reused or recycled for alternative products or fill for concrete, either when salvaging construction remnants or from a years later tear down or remodeling of a building. As a result, in some life cycles the plastic may present a potential carbon offset. Plastic also is not a food source to pest insects and fungi, nor does it have a problem with water exposure or warpage with moisture content or humidity changes. The plastic also is readily washed and cleaned on site. This makes plastic particularly desirable in areas where there is much rainfall, high water tables, other risks of moisture or water infiltration or exposure, insect activity, or a lack of available wood.

Nevertheless, in some alternative embodiments there will be requirements or objectives that will result in such alternative embodiments containing plastic admixed with other materials. For exemplary and non-limiting purpose, some load-bearing applications may benefit from incorporation of glass or other reinforcing fiber.

In some embodiments, to facilitate securement of preferred embodiment construction studadjacent the ends, caps are provided that embrace and enhance the ends and adjacent structure to which the stud is affixed. Preferred caps are illustrated indescribed herein below. In other embodiments, where predetermined lengths that will not be further cut are known and required, the ends are filled or reinforced with extra material. In yet other embodiments, where predetermined lengths, including cuts to intermediate lengths, are known and required, intermediate portions of void spaceare selectively filled or otherwise reinforced to accommodate a plurality of predetermined potential lengths used or needed at a job site.

Various embodiments of apparatus designed in accord with the present invention have been illustrated in the various figures. The embodiments are distinguished by the hundreds and tens digit, and various components within each embodiment designated by the ones digit. However, many of the components are alike or similar between embodiments, so numbering of the ones digits have been maintained wherever possible, such that identical, like or similar functions may more readily be identified between the embodiments. If not otherwise expressed, those skilled in the art will readily recognize the similarities and understand that in many cases like numbered ones digit components may be substituted from one embodiment to another in accord with the present teachings, except where such substitution would otherwise destroy operation of the embodiment. Consequently, those skilled in the art will readily determine the function and operation of many of the components illustrated herein without unnecessary additional description. In addition, various alternative embodiments will illustrate features that will be understood to be applicable to other embodiments, the relevance and desirability of which will be readily determined by a person of reasonable skill in the art upon a review of the present disclosure.

illustrates the profile view or open end view of a preferred embodiment construction studsuch as might be fabricated into the familiar 2×4 dimensional lumber geometry.illustrates a similar profile view or open end view of an alternative embodiment construction studsuch as might be fabricated into the familiar 2×6 dimensional lumber geometry. While the two embodiments are otherwise very similar, owing to the greater 5.5 inch dimension the alternative embodiment construction studhas a total of four cells, each having pairs of internal reinforcing membersarranged in an X-pattern. Each pair is separated from an adjacent pair by a cell divider and internal reinforcing member, with a total of three of these depicted.

illustrates the simple rectangular side view of preferred embodiment construction stud, showing the generally planar first sheathing faceand in this view with studlaid horizontally on the page. While as illustrated the length of preferred embodiment construction studis indeterminate, typical standard lengths for exemplary and non-limiting purpose may be 96 inches, 120 inches, and 144 inches. The side view of alternative embodiment construction studis identical thereto.

illustrate a second alternative embodiment construction stud. While most of the components are similar or like to those of preferred embodiment construction stud, second alternative embodiment construction studadditionally includes a tabwhich can be used to eliminate the need for a stud in a corner installation. The second alternative embodiment construction studand third alternative embodiment construction studillustrated ineach have this tab,,, respectively, extending in the plane of the 1.5 inch face. This tab,eliminates a stud in the corner by creating the proper spacing and contact for drywall or the like in the corners.

illustrates a fourth alternative embodiment construction stud′ similar to that of, and so is not numbered separately, but with the tab′ still originating at the corner between the planes of the 1.5 and 3.5 inch faces. However, in this fourth alternative embodiment construction stud′ the tab is running parallel to the plane of the 3.5 inch face. Once again, this tab′ is configured to eliminate a stud in the corner by creating the proper spacing and contact for drywall or the like in the corners.

illustrate a fifth alternative embodiment construction stud. While most of the components once again are similar or like to those of preferred embodiment construction stud, fifth alternative embodiment construction studis designed as a top stud, and so includes a pair of tabs. Tabsare provided extending in the plane of the side wallsand, and allow drywall to butt into the stud and provide space for trusses or ceiling joists to shrink and contract. The fifth alternative embodiment construction studand sixth alternative embodiment construction studillustrated in, respectively, each have this tab,,, respectively, extending in the plane of the side walls.

illustrate a seventh alternative embodiment construction stud. In this embodiment, the secondary fastener anchoring structure and internal reinforcingand cell divider and internal reinforcing memberof preferred embodiment construction studhas been replaced by an “I” geometry internal structure, including two internal reinforcing membersthat extend in a plane approximately parallel and relatively near to the respective generally planar first and second sheathing faces,. A long central internal reinforcing memberextends in a plane roughly centered between and parallel with the two side walls,. In this seventh alternative embodiment construction stud, a fastener driven into studfrom the generally planar first sheathing facewill pass first through outer wall, then through a small void, and then will penetrate through an adjacent internal reinforcing member. As already described herein above, this will significantly help to assure that nails, screws, and other fasteners have lasting retention. Eighth alternative embodiment construction studhas very similar internal reinforcing members in the geometry of an “I”, but in an exemplary 2×6 format rather than the exemplary 2×4 format of.

The ninth alternative embodiment construction studillustrated in, and the tenth alternative embodiment construction studillustrated ineach have geometry similar to those of the seventh alternative embodiment construction stud. However, instead of having a single long centrally located internal reinforcing member, ninth alternative embodiment construction studhas a pair of long internal reinforcing memberseach spaced a relative small distance from a most adjacent side wall,. These construction studs,provide greatly improved fastener retention irrespective of whether the fastener is driven from a sheathing face,,,, or from a side wall,,,

illustrate a preferred embodiment construction sheathing panel. As depicted, panelhas a basic sheet-like geometry, of relatively large length and width, with a relatively much smaller thickness or depth. For exemplary and non-limiting purpose, exemplary dimensions for preferred embodiment construction sheathingwill include: 4′×8′×½″ or ⅝″ for walls and flooring; or 2′×12′×½″ for ceilings. As best visible in, preferred embodiment construction sheathing panelpreferably includes a tongueand mating grooveprovided along opposed edges, most commonly the lengthwise edges. Tongueand groovework in the known manner, enabling an installer to abut sheets next to each other in a better secured and sealed interlocking manner. While not illustrated, in some embodiments a construction sheathing panel designed in accord with the teachings of the present invention has fluting to support structural requirements.

illustrate a first alternative embodiment construction sheathing panel, having a like or similar tongueand mating groove. However, in this first alternative embodiment construction sheathing panel, an interior geometry resembling that of preferred embodiment construction studis preferably provided. An outer wallforms an outer perimeter about a plurality of cells defined by cell divider and internal reinforcing members, and within each cell is provided a pair of secondary fastener anchoring structure and internal reinforcing members, each which function in like manner to the similar components found in preferred embodiment construction stud. In some embodiments, including first alternative embodiment construction sheathing panel, a thicker exterior facemay be provided, as required or desired for a particular application. In other embodiments, outer wallwill instead be of constant thickness throughout.

While the preferred and alternative embodiment studs may be of any suitable opacity, construction sheathing panels,are preferentially transparent or translucent. This allows a carpenter or other person building a structure to save time by being able to see studs such as preferred embodiment construction studthrough the sheathing, and to subsequently fasten to the stud without needing to measure and estimate the stud location and blindly fasten. In addition to the transparency or translucence of the paneling, the sheathing in most embodiments also will be paintable to enable opaqueness, custom coloring or decorating, and to reduce or prevent ultraviolet damage to the plastic. This also provides potential labor savings, by reducing the need for taping and covering of sheet rock with paint and texture.

An eleventh alternative embodiment construction studis illustrated in. Instead of having a spanning internal reinforcing member, this eleventh alternative embodiment construction studprovides internally protruding wall ribsthat provide an increased stiffness and strength without increasing the entire wall thickness, thereby keeping the overall weight and material consumption to a minimum. Wall ribsare illustrated inas being provided only on the sheathing faces,, which are the surfaces to which drywall or paneling will be attached. Nevertheless, in some alternative embodiments more and fewer internal faces of studwill be provided with wall ribs.

As illustrated in, which is grossly exaggerated to convey what would otherwise be hard to visually communicate, when a fastener such as screwor in alternative embodiments a nail or other penetrating fastener is driven into sheathing face, both sheathing faceand wall ribswill be pushed and thereby flex or deform toward the opposing sheathing face. This flexure means sheathing facewill tend to arc such that the portions of wall ribsmost protruding into the interior of studwill spread apart from adjacent like portions of wall ribs. This net effect of spreading apart adjacent wall ribswill allow fastenerto penetrate into studwith minimal additional interference from the wall ribs, relatively easier than if there were no flexure in first sheathing face

However, as illustrated in, which is also grossly exaggerated to convey what would otherwise be hard to visually communicate, when a fastener such as screwis pulled away from stud, such as when a force is applied that might tend to pull out drywall, sheeting, or other objects anchored to stud, the resulting force will tend to cause sheathing faceto arc away from the opposing sheathing face. This movement, even if slight, will cause each of the portions of wall ribsmost protruding into the center of studto be pulled closer together to adjacent like portions of wall ribs. This net effect of pulling together adjacent wall ribswill increase the force required to pull a fastener out from stud, thereby creating additional interference from wall ribs. Consequently, the addition of wall ribsincreases the force required to insert a fastener by less than these same wall ribs increase the force required to withdraw or pull out a fastener from stud. In addition, these wall ribs require both less material and less overall weight than if the outer walls of studwere simply made thicker.

As will be appreciated, in some embodiments each of the materials, dimensions and overall geometry of wall ribs, first sheathing face, and fastenercan be varied to meet the needs of a particular application. For exemplary and non-limiting purpose, the width of the valleys between protruding teeth as well as the width of the protruding teeth can each be increased or decreased such as would be appropriate to work most optimally with a particular size or type of fastener.

Twelfth alternative embodiment construction studillustrated inincorporates wall ribshaving like geometry and function to wall ribs. These wall ribsare further combined together with a pair of internal reinforcing memberseach spaced a relatively small distance from an adjacent ribbed wall. Internal reinforcing membershave like geometry and function to internal reinforcing memberof seventh alternative embodiment construction stud, and so studprovides even greater holding force and structural rigidity. As may be apparent, these construction studs,provide improved fastener retention.

illustrate preferred and alternative embodiment stud caps,. In these embodiments, both stud caps,have a solid body that caps the terminal end(s) of a stud. For exemplary purpose, stud capis configured to terminate stud, while stud capis configured to terminate stud. When properly placed into the end of a stud, as will be described herein below, fasteners can be driven into the solid core of the stud cap, allowing a carpenter to install fasteners from nearly any direction or angle, as is common practice with wood studs.

Both have similar features, including a top face,; side walls,; ribs,; and terminating caps,. As aforementioned, in preferred embodiments of stud end caps,the volume within the space defined by top face,; side walls,; and terminating caps,is solid. Nevertheless, in some alternative embodiments there will be a limited air space, and in yet other alternative embodiments there will be a predetermined web similar to internal reinforcing members such as,,, and.

As is apparent from an inspection of the two, side wallsdefine a volume that extends across almost the entire terminating cap, leaving just a small lip or overhang of terminating capexposed in. This small lip or overhang is configured to engage with outer wallwhen stud capis fully and properly inserted into the end of stud, thereby preventing stud capfrom dropping into studbeyond terminating cap. Since studhas additional internal reinforcing membersthat reduce the open void spaceto a cross-section smaller than that of void, side wallsleave a much bigger lip or overhang on terminating capexposed.

In addition, side wallsform orthogonal planes with respect to top faceand terminating cap. In contrast, side wallsare not planar, and top faceis slightly smaller as a result. Ribsare configured to engage with the interior of outer walls, creating slight plastic deformation therebetween in the manner of a cork in a bottle to ensure a good solid fit therebetween. However, and as with a cork, the slightly smaller top faceallows this face to be inserted more easily and with less precise alignment before ribswill engage with outer walls, making installation somewhat less difficult.

The features that distinguish stud end caps,from each other are provided for exemplary purpose and are not mutually exclusive. In other words, and solely for exemplary and non-limiting purpose, in some alternative embodiments the larger lip defined by terminating capwill be used in combination with planar and orthogonally arranged side walls. Further, while stud end caps,each are illustrated having a top face,that is generally planar and parallel to terminating caps,, in some alternative embodiments top faces,are provided with notches or cut-outs that correspond to the internal webbing created by such features as: the secondary fastener anchoring structure and internal reinforcing member,,,,,,,,,; cell divider and internal reinforcing member,,,,,; internal reinforcing members,,,,; long central internal reinforcing members,,,; and wall ribs,.